DE69734095T2 - POWER DISTRIBUTION UNIT - Google Patents

Description

The The invention relates to energy distribution centers or energy distribution units.

background the invention

current Motor vehicles use a fuse box or power distribution center in conjunction with a wiring harness to supply power to different Distribute components of the vehicle. The fuse box points typically a variety of fuses and many relays on and has multiple connections, into which the wiring harness is plugged, allowing energy through the vehicle can be distributed. To distribute the energy well, be multiple outputs an energy line of the vehicle battery and / or a generator divided into individual circuits, which have their own fuse or own their own relay, using wires, conductive tapes and Interfaces happens. This requires a lot of effort in terms of the wiring, typically in the form of a bulky wiring harness, and several levels to be joined together. This arrangement requires also a big one Number of parts and does not allow easy adding of circuits. For example, U.S. Patent No. 5,207,587 to Hamill et al. an energy distribution center, which has a main bus plate and two or more wire bus plates containing a plurality of wires, to make contact with tabs.

US Patent No. 5,023,752 to Detter et al. discloses an energy distribution center, which as part of its conductive Arrangement comprises a plurality of circuits or circuit levels, which single, replaceable pre-punched metal circuit components exhibit. Each pre-punched metal circuit component is replaced by held a retaining rib, which adjacent to nebeneinanderlie surfaces Circuit levels is formed to be at an adjacent circuit component Make sure they are in a line-aligned position within their cavity or its conductor track. U.S. Patent No. 5,478,244 to Maue et al. discloses a cable box comprising: a protective cover, a protective housing, two or more electrical interfaces and a variety of internal power transmitting Circuits arranged side by side within the housing are. The inner current-transmitting Circuits are connected to at least one electrical interface and have at least the following: at least one flexible printed circuit board, which is substantially flexible within the housing, and at least one Terminal strip and an insulator device.

electrical Problems relating to energy distribution in a motor vehicle, belong the most difficult problems to diagnose and repair are. Furthermore newer motor vehicles have "intelligent" modules, wherein each smart module has its own wiring harness for the fuse box requires. An example for an intelligent module is a heating / air conditioning control, which determines the instantaneous temperature within the vehicle and controls several relays that turn on the heater or the air conditioner or turn off to the environment within the motor vehicle within the desired Temperature range to maintain. It is believed that the complexity and the number of smart modules in automobiles in the future continues to grow.

presentation the invention

The present invention provides a power distribution center for a vehicle, comprising: a non-conductive housing having a connection plate provided with a frame recess having a polarizing member on one side of the frame recess and a plurality of terminal recesses including alignment walls on an opposite side of the panel wherein the plate has a harness connector with a plurality of contacts; at least one conductive assembly disposed within the frame cavity and aligned by the polarizing element, the conductive assembly comprising: a printed circuit board having a plurality of conductive etchings formed thereon and a plurality of terminals disposed on the printed circuit board ; a leadframe assembly comprising a nonconductive substrate having at least one lead frame stamping member attached thereto, the leadframe assembly being disposed within the frame well above the at least one conductive assembly, the nonconductive substrate isolating the at least one lead frame stamping from the circuit board; an insulator disposed within the recess above the leadframe assembly, the insulator having a plurality of slotted holes for each passing one of the plurality of lead terminals and the lead frame stamping parts therethrough; and a power supply terminal strip having a power supply terminal having a plurality of terminals extending therethrough, the strip being disposed within the frame cavity above the insulator; a non-conductive alignment plate having a plurality of slotted holes for letting those of the plurality of terminal parts and the leadframe stamping parts therethrough and a plurality of recesses to be formed therein To receive components, wherein the non-conductive alignment plate is disposed within the frame recess above the power supply terminal strip; and a non-conductive cover removably attached to the non-conductive housing, the non-conductive cover including the space for receiving the components when mounted.

at a preferred embodiment According to the invention, the power distribution center distributes energy from one Terminal strip within the power distribution center by relay, Fuses and other electronic devices to a printed circuit board and / or Terminal frame assembly to connections for distribution of energy to supply by the vehicle. The energy distribution center may also also an insulator, an alignment plate and a cover exhibit.

at a particular embodiment become the leadframe assembly or the printed circuit board assembly used to distribute energy within the energy distribution center. The circuits become lead frames or PCB tracks assigned based on current thresholds, by the design requirements and / or other appropriate considerations have been set up. The power distribution center is configured to a simple addition to enable electronic modules by creating an interface as part of the energy distribution center which makes modules possible will be added to be without for Each module requires a separate wiring harness. connecting clips are used to share the fuses and the relays connect the connector, the circuit board and the terminal strip. The connection clips have a low profile, create one direct male-female contact and are secured to the connector clip to hold on the connection part.

short descriptions the drawings

The The invention will become apparent from the following detailed description in conjunction with the attached Drawings better understood, in which:

1 a representation of an embodiment of an energy distribution center according to the present invention;

2 an isometric view of the housing / connection plate of the energy distribution center of 1 ;

3 a plan view of a circuit board of the energy distribution center of 1 ;

3A an illustration of a printed circuit board connection part;

4 an isometric view of the terminal frame assembly of the energy distribution center of 1 ;

4A an isometric view of a first lead frame;

4B an isometric view of a second lead frame;

4C an isometric view of a third lead frame;

4D an isometric view of a fourth port frame;

4E an isometric view of a fifth lead frame;

5 an isometric view of the insulator of 1 ;

6 an isometric view of the B + terminal strip assembly of 1 ;

7 an isometric view of a terminal clip, which is arranged on a B + terminal strip, wherein it matches with a component connecting part;

7A an isometric view of a connector clip;

7B an isometric front view of the connection clip of 7A which is installed on a terminal tongue;

7C an isometric rear view of the terminal clip of 7A which is installed on a terminal tongue;

8th an isometric view of an alignment plate of 1 ;

9 a representation of another embodiment of an energy distribution center;

9A an isometric view of the housing / connection plate of the energy distribution center of 9 ; and

9B a plan view of the energy distribution center of 9 ,

detailed Description of the invention

In 1 is in an exploded view an energy distribution center (ECC) 1 represented according to the present invention. While a particular embodiment is described, it should be appreciated that other embodiments employing particular portions of the present invention should also be considered. The ECC 1 creates a simple, efficient distribution of energy within a motor vehicle. The ECC 1 has one or more external connections 12 to a power supply terminal or power bus such. B. a connection from the vehicle battery or a generator. The ECC 1 has a plurality of relays in this embodiment 14 and fuses 16 and 18 as well as other active and passive electronic devices. The ECC 1 indicates: a housing / connection plate 10 , a circuit board 30 , a lead frame assembly 40 , an insulator 50 , a B + terminal strip assembly 60 , a connection alignment plate 100 and a cover 110 , A special embodiment of the ECC points 14 Relay (1 spare part), 15 Mini fuses (2 spare parts), and 14 Cartridge fuses (2 spare parts).

In 2 is a housing / connection plate 10 shown. The housing / connection plate 10 has a plastic injection molding or other non-conductive material, and is with a plurality of alignment walls 22 for aligning and securing the mating harness connections (not shown) when inserted into the housing / connection plate 10 have been used. The output connector side walls 22 have a locking mechanism to prevent the harness connector from disengaging when the harness is inserted into the connector. The locking mechanism may include a ribbed piece, a latch, or a bolt support. The housing / connection plate 10 Holds all parts of the EVC that are aligned within the ECC and is for easier assembly and alignment within the ECC 1 poled.

In 3 is a circuit board assembly 30 shown. The printed circuit board assembly is double-layered in this embodiment. While a specific embodiment of the circuit board will be described, it will be understood that circuit boards made of different materials having different dimensions and different conductors may also be used. The circuit board provides many connections from a first side of the fuses and / or relays (the second side of the fuses and / or the relays directly connect the B + connection strip) to the harness connectors and distributes energy from the B + connection strip (not shown) to different circuits and components.

The circuit board 30 has many mechanically inserted and / or soldered conductive connectors 32 on, like one of them in 3A is shown. In a specific embodiment, the connector part 32 6.35 mm standard plugs, 2.80 mm standard plugs, modified 6.35 mm plugs to accept a terminal clip, modified 2.80 mm plugs to accept a terminal clip, or various combinations thereof. The circuit board 30 is in the EVZ housing / connection plate 10 during the assembly of the ECC 1 inserted from the top. The 6.35 mm connector is used to connect the circuit board 30 with one or more plug fuses 16 to be contacted while also being used as an output part of the harness connector. The 2.80 mm connector is used as an output part to the harness connector. The modified 2.80 mm connectors and the modified 6.35 mm connectors are used to interface with the connector clips. The connection clips are used to interface with a mini-fuse 18 or to create an ISO relay. The circuit board 30 is configured to be in the ECC 1 fits, and it is there on one side by the housing / connection plate and on the other side by a leadframe assembly 40 secured, which is described below.

In 4 is a lead frame assembly 40 which is a non-conductive substrate 41 comprising plastic or the like. Many conductive leadframe stampings 45 to 49 are mechanically connected to the non-conductive substrate. The plastic substrate 41 creates an isolation plane between the circuit board assembly 30 and the lead frame stampings 45 to 49 , The leadframe arrangement 40 also has many slots 43 through which the PCB connector parts 32 pass through. During the assembly of the ECC 1 becomes the leadframe assembly 40 inserted into the housing / connection plate from above.

In the 4A to 4E a group of different terminal frame stampings is shown. While five lead frame stampings are illustrated, it will be understood that other lead frame stampings including various aspects as disclosed below are also possible. In 4A is a first terminal frame stamping 45 dargestelt, which is a plug-in part 90 for connecting a cartridge fuse, and having a modified terminal part which can be used for a terminal clip to be connected to a miniature fuse or an ESO relay. The modified part 95 has a stamped round area 92 , a pair of locking hooks 91 , Edge channels or window 93 and a tapered tip section 94 to secure a connection clip to it. In 4B a second connection frame part is shown, which has three modified connection parts 95 has to connect different terminals of a mini-fuse or an ISO-relay with each other. In 4C a third terminal frame stamped part is shown, which is a single male part 90 for connecting to a fuse and a pair of modified parts 95 for connecting different terminals of a relay or a fuse by means of a connection clip. In 4D is a fourth leadframe stamping with a single male part 90 , a single modified connector 95 and a harness connection terminal 97 shown. In 4E a fifth connector is shown, which is a single connector 95 and a single harness connection terminal 97 having.

An insulator 50 , please refer 5 , separates the B + connection strip 60 from the lead frame stampings 45 - 49 , With the insulator 50 becomes a position assurance by means of a pattern of slotted holes 51 with all printed circuit board connection parts 32 and lead frame stampings 45 - 49 before installing connection clips 82 and 82 ' created. The insulator 50 fits as a third mounting component from above into the housing / connection plate, with the insulator 50 itself and the previously used mounting parts within the housing / connection plate holds.

How out 6 As can be seen, the B + terminal strip arrangement leads 60 Power directly to one side of the fuses and relays. The B + terminal strip has a unitary stamped metal part capable of transferring large currents. The B + terminal strip assembly 60 has a pair of bolts 12 to receive a power supply cable from a vehicle battery or a generator. The B + terminal strip assembly 60 has many 2.80 mm connection clips in this embodiment 84 , which have been installed to accommodate the terminals of mini-fuses, and the arrangement 60 has many 6.35 mm connection clips 84 ' to pick up the connections of relays. The B + connection strip 60 also has many connectors 55 for cartridges securing connections, connecting parts 52 for securing connections and connecting parts 54 for relay connections. The B + terminal strip assembly 50 is installed in the port alignment plate for positioning accuracy and mechanically fixed therein to prevent torque coupled assembly which may occur during final assembly.

In 7 is a connection clip 84 shown, which on a connection part 52 of the B + connection strip 50 is installed, with in 7 how a connector part from a fuse or a relay mates with a connector as a system is shown. In the 7A to 7C are connection clips 84 and 84 ' shown. The connection clip 84 can be configured to connect to a 2.80 mm connector while the connector clip 84 ' can be configured to fit on a 6.35 mm connector. The terminal clip may be made of a conductive material, an insulating material or an insulating material with a conductive coating, and may have a single unitary part. In a particular embodiment is a pair of windows with windows 86 configured to receive locking ramps of the modified connectors therein and secure the connector clip to the connector. A folded section or a biased element 85 creates a strong counterforce to secure the clip with the connector and the connector to the connector of a relay or fuse when the relay or fuse in the connector clip 84 is used.

On connectors mounted on the PCB 32 , on the connection frame connections 95 and the B + terminal strip connectors 52 and 54 will be suitable connection clips 84 and 84 ' Installed. The connecting parts 84 and 84 ' Foresee a reversal of male connectors in female connectors. The terminal clips create counterforces so that fixture fittings will interface with component fittings within the ECC, allowing the terminal clips to be installed and verified in an automated process. Since the terminal clips provide a direct mating of the fuse or relay with the connector in a surface to surface configuration, there is only one connection plane between the connector and the part of the fuse or the relay, unlike known devices which provide a double jack interface. in that one end of the double-socket interface connects one terminal and the other end connects a device, so that two connection levels are required. Thus, the present terminal clip is more effective and reliable due to the lower number of interconnect levels.

How out 7 to 7C is apparent, is a connection clip 84 shown on a connector 52 a B + connection strip is installed. When the mating terminal of a relay or fuse 89 in the connection part 84 is inserted creates the biasing element 84 a strong counterforce to the mating contact 89 in mechanical and electrical contact with the connector 52 of the B + terminal strip. There is only ONE single connection plane between the terminal part of the B + terminal strip and the mating terminal part in contrast to a conventional double plug-in clip. Further, by using only a single connection plane, the height of the interface is reduced.

In 8th is an alignment plate 100 shown. The alignment plate 100 has a non-conductive material, with a plurality of terminals 104 which allows connectors and / or pins to pass through there. The alignment plate also has many recesses 105 to accommodate cartridge backups. In addition, the alignment plate keeps the connectors in line and thus prevents inadvertent shorting from one connector to another.

The enclosure / connector plate with all previously installed levels, all installed fuses and relays will then be ready to install the cover in a final assembly step 110 , All components and intermediate layers are inserted from one side and poled so that incorrect assembly is not possible.

Like from the 9 to 9B It can be seen that there is an additional embodiment of an energy distribution center 10 ' shown. This embodiment is similar to the embodiment described above, except that in this embodiment a single bolt 12 and only two output connectors 22 and 24 can be used as out 8th is apparent. In this embodiment is also an electronic module interface 50 shown. The electronic module interface may be provided as an integral part of the power distribution center or provided as an additional part. The electronic module interface may also be used with other embodiments of the ECC as a separate add-on module. Electronic modules include, but are not limited to, multiplex interfaces, body control modules, diagnostic modules, and the like. A direct connection to these modules results in fewer wires and fewer wiring connections within the vehicle.

In 9A is the housing / connection plate 10 ' shown, which is used for new vehicles, the plate 10 ' side walls 22 comprising a first output connector 24 surrounds for receiving a powertrain harness (not shown). A second output connector 26 is configured to receive a body harness (not shown).

The ECC 1 Improves reliability by reducing the number of wires and interconnections, reducing new warranty claims for new vehicles. The ECC can be manufactured using automated assembly equipment, can allow for automated testing during manufacturing, and prevents improper insertion of components.

By doing preferred embodiments of the invention, however, one of ordinary skill in the art, that other embodiments, which have these concepts can be used. Accordingly, it is pointed out that the invention is not limited to the described embodiments is limited but limited only to the scope of the appended claims is.

Claims (10)

Energy distribution center for a vehicle, comprising: a non-conductive housing having a connection plate ( 10 ), which is provided with a frame recess is provided with a polarizing element on one side of the frame recess and a plurality of terminal recesses which on an opposite side of the plate ( 10 ) Alignment walls ( 22 ), the plate having a harness connector with a plurality of contacts; at least one conductive assembly disposed within the frame cavity and aligned by the polarizing element, the conductive assembly comprising; a circuit board ( 30 ) having a plurality of conductive etchings formed thereon; and a plurality of connecting parts ( 32 ) on the printed circuit board ( 30 ) are arranged; a lead frame assembly ( 40 ), which is a non-conductive substrate ( 41 ) has at least one terminal frame stamping part ( 45 to 49 ), which is attached thereto, wherein the leadframe arrangement ( 40 ) is arranged within the frame recess above the at least one conductive arrangement, wherein the non-conductive substrate, the at least one terminal frame punched part ( 45 to 49 ) from the printed circuit board ( 30 isolated; an insulator ( 50 ), which within the recess above the leadframe assembly ( 40 ), the insulator ( 50 ) a plurality of slotted holes ( 51 ) in each case one of the plurality of connecting parts ( 32 ) and the lead frame stampings ( 45 to 49 ) to let it through there; and a power supply terminal strip ( 60 ) with a power supply connection and a plurality of connection parts ( 55 ), which extend therethrough, wherein the strip within the frame recess above the insulator ( 50 ) is arranged; a non-conductive alignment plate ( 100 ) with a plurality of slotted holes ( 104 ) to those of the plurality of connecting parts ( 32 ) and the lead frame stampings ( 45 to 49 ) and a plurality of recesses ( 105 ) to contain components therein, the non-conductive alignment plate ( 100 ) within the frame recess above the power supply terminal strip ( 60 ) is arranged; and a non-conductive cover ( 110 ), which with the non-conductive housing ( 10 ) is releasably attached, wherein the non-conductive cover ( 110 ) includes the space for accommodating the components when attached. An energy distribution center according to claim 1, further comprising a plurality of terminal clips ( 84 ) configured to receive a predetermined number of the conductive device terminals ( 32 ), the leadframe stamping parts and the connecting parts ( 52 ) of the power supply terminal strip to a component. Energy distribution center according to claim 2, wherein the Component has a fuse. Energy distribution center according to claim 2, wherein the Component has a relay. The power distribution center of claim 1, further comprising an energy distribution center module having an electronics module interface ( 15 ), wherein the power distribution center module is disposed within the power distribution center. Energy distribution center according to claim 5, wherein the electronic module interface ( 15 ) has a multiplex interface. Energy distribution center according to claim 5, wherein the Module is detachably formed by the power distribution center. Energy distribution center according to claim 5, wherein the Module interface integrally formed with the power distribution center is. Energy distribution center according to claim 2, wherein the Variety of connection clips are selected from the group, which has 2.80 mm connection clips and 6.35 mm connection clips. Energy distribution center according to claim 1, wherein the Wiring harness connector is configured to connect with a vehicle wiring harness fits together.